Diagnostic element for validation of bolt detection of a guard locking switch in a static state

ABSTRACT

An industrial locking switch includes an inductive sensing circuit that uses a non-contact technique to detect when the switch&#39;s locking bolt has transitioned to the lock position. The inductive sensing circuit can comprise an inductive coil, a capacitor, and a converter that converts a frequency of a current signal through the inductive coil to a digital frequency value. A controller detects when the locking bolt has advanced to the lock position by monitoring the digital frequency value for frequency shifts indicative of a disturbance of the induction coil&#39;s magnetic field by the locking bolt. To validate operation of the inductive sensing system without requiring actuation of the locking bolt, a diagnostic switch connects a diagnostic capacitor to the inductive circuit to simulate the frequency shift caused by the locking bolt, and the inductive sensing system is validated if the expected frequency shift is detected.

BACKGROUND

The subject matter disclosed herein relates generally to industrialsafety locks, and, more particularly, to internal locking switch sensingand diagnostics.

BRIEF DESCRIPTION

The following presents a simplified summary in order to provide a basicunderstanding of some aspects described herein. This summary is not anextensive overview nor is intended to identify key/critical elements orto delineate the scope of the various aspects described herein. Its solepurpose is to present some concepts in a simplified form as a prelude tothe more detailed description that is presented later.

In one or more embodiments, a locking switch is provided, comprising asolenoid-driven locking bolt configured to engage with an engagementhole of a locking tongue when advanced to a locking position; and aninductive sensor system configured to detect that the locking bolt hasadvanced to the locking position, wherein the inductive sensor systemcomprises a tank circuit comprising an inductive coil and a capacitor,the inductive coil oriented to receive the locking tongue when thelocking tongue is advanced to the locking position, a converterconfigured to convert a frequency of a current signal on the tankcircuit to a digital frequency value, and a master controller configuredto generate a lock detection signal in response to determining that ashift in the digital frequency value corresponds to an expectedfrequency shift of the current signal induced by the inductive coil inresponse to advancement of the locking bolt; and a diagnostic systemconfigured to confirm operation of the inductive sensor system, thediagnostic system comprising a diagnostic capacitor and a diagnosticswitch configured to connect the diagnostic capacitor to the tankcircuit in parallel with the capacitor.

Also, a system for sensing a position of a locking bolt of an industriallocking switch is provided, comprising an inductive circuit comprisingan inductive coil and a capacitor electrically connected in parallel,wherein the inductive coil is positioned to receive a locking bolt of anindustrial locking switch when the locking bolt is transitioned to alock position; a converter configured to convert a frequency of acurrent signal on the inductive circuit to a digital frequency value; amaster controller configured to generate a bolt detection signal inresponse to determining that the digital frequency value changes by anamount equal to or substantially equal to a defined frequency shiftcorresponding to a frequency shift induced by the inductive coil inresponse to presence of the locking bolt within the inductive coil'smagnetic field; and a diagnostic system configured to validate operationof the inductive circuit and the converter, the diagnostic systemcomprising a diagnostic capacitor and a diagnostic switch configured toelectrically connect the diagnostic capacitor to the inductive circuitin parallel with the capacitor.

Also, method for validating operation of a locking bolt detection systemis provided, comprising in response to initiation of a diagnostic test,connecting a diagnostic capacitor in parallel with a capacitor of aninductive sensing circuit configured to detect that a locking bolt of anindustrial locking switch has advanced to a locking position, whereinthe inductive sensing circuit comprises the capacitor and an inductivecoil; and in response to determining that a frequency of a currentsignal through the inductive sensing circuit does not change, within adefined duration after the connecting of the diagnostic capacitor, by anamount equal to or substantially equal to a frequency shift caused bypresence of the locking bolt in the inductive coil's magnetic field,generating an error message indicating that the inductive sensingcircuit is not operating correctly.

To the accomplishment of the foregoing and related ends, certainillustrative aspects are described herein in connection with thefollowing description and the annexed drawings. These aspects areindicative of various ways which can be practiced, all of which areintended to be covered herein. Other advantages and novel features maybecome apparent from the following detailed description when consideredin conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an example locking switch andcorresponding locking tongue.

FIG. 2a is a right side view of an example locking switch.

FIG. 2b is a front side view of the example locking switch.

FIG. 2c is a left side view of the example locking switch.

FIG. 3 is a perspective close-up view of the top of an example lockingswitch.

FIG. 4 is a perspective view of an example actuator assembly thatincludes an RFID tag that can be detected by RFID coils housed in alocking switch.

FIG. 5a is a perspective view of the top of a locking switch with thecasing of the switch's head removed, revealing the switch'ssolenoid-driven locking bolt.

FIG. 5b is a perspective view of the top of an example locking switchwith both the casing of the switch's head and the switch's coil housingremoved.

FIG. 6 is a perspective, cross-sectional view of a bobbin assembly.

FIG. 7 is a cross-sectional top view of a locking switch with a lockingtongue inserted into the switch's front facing entry slot.

FIG. 8 is a perspective view depicting relative positions of an actuatorassembly and RFID coils when the actuator assembly's locking tongue isinserted into an entry slot of a locking switch.

FIG. 9 is a top view of an example tongue component that can be used inan actuator assembly to prevent premature detection due to parasiticeffects.

FIG. 10 is a cross-sectional view of a locking switch's head with anactuator assembly inserted and engaged with the locking switch.

FIG. 11 is a graph that plots sensor inductance shift as a function ofsensor frequency for a variety of materials.

FIG. 12 is a generalized diagram of an example validation circuit thatincludes diagnostic circuitry capable of confirming the locking switch'sbolt detection capability without interrupting the function of theswitch.

FIG. 13 is a generalized diagram of another example embodiment of alocking bolt validation circuit including diagnostic circuitry.

FIG. 14 is a flowchart of an example methodology for detecting insertionof a locking tongue of an actuator assembly into an industrial lockingswitch from any of three different directions of approach.

FIG. 15 is a flowchart of an example methodology for validating correctoperation of an inductive sensor used to detect the position of thelocking bolt of an industrial locking switch.

FIG. 16 is an example computing environment.

FIG. 17 is an example networking environment.

DETAILED DESCRIPTION

The subject disclosure is now described with reference to the drawings,wherein like reference numerals are used to refer to like elementsthroughout. In the following description, for purposes of explanation,numerous specific details are set forth in order to provide a thoroughunderstanding thereof. It may be evident, however, that the subjectdisclosure can be practiced without these specific details. In otherinstances, well-known structures and devices are shown in block diagramform in order to facilitate a description thereof.

In addition, the term “or” is intended to mean an inclusive “or” ratherthan an exclusive “or.” That is, unless specified otherwise, or clearfrom the context, the phrase “X employs A or B” is intended to mean anyof the natural inclusive permutations. That is, the phrase “X employs Aor B” is satisfied by any of the following instances: X employs A; Xemploys B; or X employs both A and B. In addition, the articles “a” and“an” as used in this application and the appended claims shouldgenerally be construed to mean “one or more” unless specified otherwiseor clear from the context to be directed to a singular form.

Furthermore, the term “set” as employed herein excludes the empty set;e.g., the set with no elements therein. Thus, a “set” in the subjectdisclosure includes one or more elements or entities. As anillustration, a set of controllers includes one or more controllers; aset of holes includes one or more holes; etc.

Various aspects or features will be presented in terms of systems thatmay include a number of devices, components, modules, and the like. Itis to be understood and appreciated that the various systems may includeadditional devices, components, modules, etc. and/or may not include allof the devices, components, modules etc. discussed in connection withthe figures. A combination of these approaches also can be used.

Many industrial machines, robots, or automation systems are protected bysafety guarding or fencing that surrounds the hazardous area, forming aprotected cell. This safety fencing typically includes a lockable safetygate to allow operator access to the protected area only while themachine or system is not operating and is otherwise in a safe state.Solenoid-driven locking switches are often used to lock these safetygates in the closed position while the protected machine or system isoperating in automatic mode and all associated safety devices are intheir safe statuses, thereby preventing operator access to the hazardousarea while the machine is running.

FIG. 1 is a perspective view of an example locking switch 102 andcorresponding locking tongue 108. The locking switch 102 is typicallymounted to either the frame on which the gate is mounted or on the gateitself. The corresponding locking tongue 108 is mounted on the oppositegate component (either on the gate or on the frame) such that the tongue108 aligns with an entry slot 110 on the locking switch 102. The lockingtongue 108 is generally ring-shaped, having a square or circularengagement hole 112 configured to receive and engage with the switch'sinternal solenoid-driven locking bolt when the bolt is advanced (notshown in FIG. 1).

When the gate is in the closed position, the locking tongue 108 isreceived in the entry slot 110 of the locking switch 102. While theprotected machine or automation system is in automatic mode or isrunning, the locking switch 102 actuates a solenoid-driven locking boltupward through the engagement 112 of the locking tongue 108, preventingremoval of the locking tongue 108 from the locking switch 102 andthereby preventing the gate from being opened. Some locking switches 102are electrically connected to the machine cell's safety system such thatthe machine or automation system cannot be placed in automatic modeunless the locking tongue 108 is engaged with the locking switch 102.

Example locking switch 102 comprises a main body 104 that houses thesolenoid and retractable bolt (while retracted) and a attached head 106on which the entry slot 110 is formed. Head 106 is removably attached tothe body 104 and can be attached to the body 104 in a selectedrotational orientation so that the entry slot 110 faces a selected oneof three or four possible directions oriented at 90 increments.

In some installation scenarios, an installer or engineer may not have apriori knowledge of the direction from which the tongue 108 willapproach the locking switch 102, which may depend on the availablemounting options for the tongue 108 and the switch 102. In otherscenarios, even if the direction of approach is known, it may benecessary to rotate the switch 102, or to rotate the head 106 relativeto the switch, so that the entry slot 110 faces the direction from whichthe tongue 108 will approach. The structural parameters of the lockingswitch 102 can limit available mounting options, or may require alabor-intensive mechanical reconfiguration of the locking switch 102 inorder to accommodate the requirements of a given mounting scenario.

To address these and other issues, one or more embodiments describedherein provide a locking switch configured to accommodate multipledirections of approach of a corresponding locking tongue 108 without theneed to rotate the head, body, or switch as a whole. To facilitatedetection of the tongue from each of these multiple directions, multipleradio frequency identifier (RFID) coils are also installed in the headof the sensor, each of which is capable of detecting an RFID tag on thetongue when the tongue has been inserted into an entry slot.

FIGS. 2a, 2b, and 2c are right side, front, and left side views of anexample locking switch 202 according to one or more embodiments. FIG. 3is a perspective close-up view of the top of locking switch 202. Similarto example switch 102, locking switch 202 comprises a main body 210 thathouses the solenoid, locking bolt mechanism, and other electrical andelectronic components. A cable port 206 is formed on the body housing210 to receive power and signal cabling that interfaces with theswitch's internal circuitry. Switch 202 also comprises a head 208mounted to the main body 210. In contrast to head 106 of switch 102,head 208 comprises three entry slots 204 a, 204 b, and 204 c. A firstentry slot 204 b is formed on a front side of head 208, while entryslots 204 a and 204 c are formed on the right and left sides of head208, respectively. This configuration supports three orthogonaldirections of approach of a corresponding locking tongue without theneed to rotate the head 208 relative to the body 210, or to rotate theswitch 202 as a whole.

Embodiments of locking switch 202 can include detection circuitry thatdetects when the tongue has been inserted into any of the three entryslots 204 a, 204 b, or 204 c, indicating that the locking bolt can beadvanced in order to properly engage with the locking tongue. In someembodiments, this detection circuitry can control an output signal (e.g.sent via a cable installed through cable port 206) that indicateswhether the locking tongue is inserted into one of the entry slots 204a, 204 b, or 204 c. In some implementations, this output signal may beused to control when the locking bolt transitions from the retracted(unlocked) position to the advanced (locked) position.

FIG. 4 is a perspective view of an example actuator assembly 402 thatcan be used with locking switch 202, and which includes an RFID tag 404that can be detected by RFID coils housed in the switch 202 (to bediscussed in more detail below). Actuator assembly 402 comprises a base408 in which is mounted a locking tongue 412 (or locking key) configuredto engage with any of the entry slots 204 a, 204 b, or 204 c of lockingswitch 202. Mounting holes 414 are formed through base 408 and can beused in connection with mounting hardware to mount the actuator assembly402 to a structure (e.g., the frame on which a safety gate is mounted orthe gate itself).

Locking tongue 412 is formed on one end of an actuating shaft 406, andthe other end of actuating shaft 406 is installed within a recess 416 ofbase 408. In the example depicted in FIG. 4, tongue 412 has formedtherein a substantially square bolt engagement hole 410 configured toreceive the locking switch's locking bolt when the bolt is advanced,although bolt engagement holes of other shapes are also within the scopeof one or more embodiments. RFID tag 404 is mounted in the tongue 412within a circular mounting feature (e.g., a hole or recess) formed inthe tongue 412 adjacent to the bolt engagement hole 410. When tongue 412is inserted within any of the entry slots 204 a, 204 b, or 204 c, RFIDcoils mounted in the locking switch's head 208 can detect the presenceof the RFID tag 404 and thereby confirm that the tongue 412 is insertedinto the locking switch 202 and that the locking bolt can be engaged.

FIG. 5a is a perspective view of the top of locking switch 202 with thecasing of head 208 removed, revealing a bushing 502 within which ishoused the solenoid-driven locking bolt that, when advanced, engageswith the inserted tongue 412. A coil housing 504 is mounted above thelocking bolt bushing 502 on the ceiling 514 of locking switch 202. FIG.5b is a perspective view of the top of locking switch 202 with both thecasing of head 208 and the coil housing 504 removed. Enclosed within thecoil housing 504 are three RFID coils 506 electrically connected inseries, each coil 506 corresponding to a different one of the threeentry slots 204 a, 204 b, and 204 c. When head 208 is in place, eachcoil 506 is oriented above one of the entry slots 204 a, 204 b, and 204c to facilitate detection of the tongue's RFID tag 404. Theseries-connected RFID coils 506 are components of a detection circuithoused in the locking switch 202, which controls an output signal basedon detection of the presence of the RFID tag 404.

As shown in FIG. 5b , RFID coils 506 are mounted on bobbin 508, which ismounted to the ceiling 514 of the locking switch 202. FIG. 6 is aperspective, cross-sectional view of a bobbin assembly 602 comprisingbobbin 508 and coils 506 a, 506 b, and 506 c. Bobbin 508 has asubstantially round profile and a top surface (or coil mounting surface)that slants upward from its edge to its center, yielding a top surfacehaving a degree of tilt θ relative to the bottom surface (that is, thesurface that mounts to the locking switch's housing). In an exampleembodiment θ may be approximately 38 degrees. However, other degrees oftilt are also within the scope of one or more embodiments. An opening512 is formed in the center of bobbin 508 and is configured to receivethe locking bolt when the bolt is advanced.

RFID coils 506 a, 506 b, and 506 c are mounted on the slanted topsurface of bobbin 508. As a result, when bobbin 508 is mounted in thelocking switch 202, each RFID coil 504 is tilted relative to the planeof the ceiling 514 such that the coil's axis—and consequently the coil'ssensing field—is directed outward from the center of the bobbin 508.Tilting the RFID coils 504 in this manner can increase the lateralsensing distance of each RFID coil 504, allowing the tongue's RFID tag404 to be detected before the tongue 412 is fully inserted into theentry slot 204. This feature, together with the relatively large size ofthe tongue's engagement hole 410, can promote a large degree ofmechanical freedom when aligning the engagement hole with locking bolt,as discussed in more detail below.

FIG. 7 is a cross-sectional top view of locking switch 202 with thetongue 412 of actuator assembly 402 inserted into the front facing entryslot 204 b. FIG. 8 is a perspective view depicting relative positions ofthe actuator assembly 402 and RFID coils 506 a, 506 b, and 506 c whenthe tongue 412 is inserted into the front facing entry slot 204 b (forclarity, FIGS. 7 and 8 depict RFID coils 506 as being oriented to residein the same plane rather than being tilted; however, in some embodimentsthe RFID coils 506 will be tilted by bobbin 508 as shown in FIGS. 5b and6). As shown in these figures, bolt engagement hole 410 aligns with thelocking bolt 702 and RFID tag 404 resides below RFID coil 506 whiletongue 412 is inserted into the entry slot 204. RFID coils 506 a, 506 b,and 506 c are connected in series and are electrically driven bydetection circuitry 802 inside the sensor's housing to generate threeseparate electromagnetic fields. This detection circuitry 802 includesan RFID transceiver that detects disturbances to any of the threeelectromagnetic fields due to the presence of RFID tag 404 within rangeof the electromagnetic field. Such disturbances modulate an RFID currentsignal into the detection circuitry 802, which detects the presence ofthe tongue 412 based on these current signal modulations.

Since RFID coils 506 a, 506 b, and 506 c are connected in series,disturbances to any of the three electromagnetic fields generated by therespective three coils 506 are detected by the RFID transceiver ofdetection circuitry 802. Thus, a single RFID transceiver can be used todetect entry of the tongue 412 into any of the three entry slots 204 a,204 b, and 204 c, mitigating the need for three separate RFIDtransceivers. This configuration can also yield a relatively fastresponse time, since the tongue's RFID tag 404 can be detected frommultiple directions by monitoring only one signal, without the need tomultiplex signals or analyze multiple signal lines. In some embodiments,the middle RFID coil 506 b can be flipped in polarity relative to thepolarities of RFID coils 506 a and 506 c, partially cancelling themagnetic field in the center of coil 604 and reducing interfere of theRFID signal on the bolt detection signal.

FIG. 9 is a top view of an example tongue component 906 that can be usedin the actuator assembly 402 to prevent premature detection due toparasitic effects. As shown in this figure, tongue component 906comprises a gap 904 that runs from the edge of RFID tag mounting hole902 (in which the RFID tag 404 resides) through the entire length of thearticulating shaft 406, splitting the articulating shaft 406 along itslengthwise axis. Gap 904 is designed to mitigate potential parasiticeffects of the metal tongue component 906 that could otherwise cause thetongue 412 to act as an antenna in the presence of the RFID coils'magnetic fields, resulting in premature detection of the tongue 412before the tongue is inserted to a viable locking depth.

This electrical configuration, together with the mechanical design ofthe locking switch's head 208, affords a degree of installationflexibility by supporting three different directions of approach of thetongue 412 without the need to rotate head 208 or, in some cases, tore-orient the locking switch as a whole. This arrangement is supportedby an electrical detection system that can detect entry of the tongue412 from any of the multiple directions by monitoring a singleelectrical signal with one sensor.

As noted above, RFID coils 506 can be tilted outward by virtue of theslanted surface of bobbin 508 (see FIG. 6). This extends the sensingdistance of each RFID coil 506 and allows the detection circuitry 802 todetect the tongue's RFID tag 404 before the tongue 412 is fully insertedinto an entry slot 204. This extended detection distance can work inconjunction with an engagement hole 410 that is sized to be considerablylarger than the locking bolt 702 to introduce a large degree ofmisalignment tolerance between the tongue 412 and the locking bolt 702.That is, sizing the tongue's engagement hole 410 to be larger than thecross-sectional profile of the locking bolt 702 allows the locking bolt702 to successfully engage with the tongue's engagement hole across alarger range of tongue insertion depths than would be possible if theengagement hole 410 was sized more closely to the locking bolt'sprofile. Since this design does not require the tongue 412 to be fullyinserted into an entrance slot 204 before the locking bolt 702 can beengaged, the extended sensing distance that results from tilting of theRFID coils 506 as shown in FIG. 6 can facilitate detection of the RFIDtag 404 at the earliest insertion position at which the locking bolt 702can be safely advanced while ensuring reliable engagement with theengagement hole 410.

In some embodiments, a further degree of misalignment tolerance betweenthe tongue 412 and the locking switch 202 can be achieved by designingthe actuator assembly 402 such that the tongue 412 can articulate withinthe base 408 to a limited degree. Returning to FIG. 4, tongue 412 isformed on one end of an articulating shaft 406 that is mounted within arecess 416 of base 408. The shaft 406 is unrestrained in the x-y plane(that is, the plane parallel with the front face of the base 408),allowing the shaft 406 and tongue 412 to pivot away from its normal axisrelative to base 408 within the bounds of recess 416. In someembodiments, the shaft 406 may also be afforded limited sliding movementalong the z-axis (perpendicular to the face of base 408). Designing theactuator assembly 402 to permit a limited degree of tongue articulationin this manner further increases the misalignment tolerance between thetongue 412 and the locking switch 202, allowing the tongue 412 to beinserted into an entry slot 204 and engaged with the locking bolt 503even if the tongue 412 is imperfectly aligned with these switchcomponents.

Returning now to FIG. 6, some embodiments of bobbin assembly 602 mayalso include an inductive coil 604 mounted within the opening 512 of thebobbin 508. Coil 604 is part of an LC tank circuit housed within theswitch housing used to detect and confirm that the locking bolt 702 hasbeen advanced. FIG. 10 is a cross-sectional view of the locking switch'shead 208 with actuator assembly 402 inserted and engaged with thelocking switch. For clarity, the bobbin 508 is omitted from this view toillustrate the positions of RFID coils 506 and inductive coil 604. An LCtank circuit including inductive coil 604 in parallel with a capacitor(not shown in FIG. 10) acts as an inductive sensor that detects when thelocking bolt 702 is in the advanced position. For example, the circuitcan drive an alternating current through the coil 604, where thefrequency of the current is a function of the inductance of the coil604. Inductive coil 604 resides along the edge of the bobbin's centralopening 512 so that locking bolt 702 passes through the coil 604 whenadvanced to the locked position. While locking bolt 702 is in theadvanced (locked) position, the presence of the metal locking bolt 702within the coil's magnetic field changes the inductance of the coil 604,and thus changes the frequency of the current signal. This change in thefrequency of the current signal is detected by the LC tank circuit whichgenerates a confirmation signal in response, indicating that the lockingbolt 702 is in the advanced position. Thus, inductive coil 604 and itsassociated LC tank circuit provide a non-contact method for confirmingthat locking bolt 702 has properly advanced and engaged with tongue 412.The use of an inductive sensor allows the position of locking bolt 702to be detected without the use of a magnet or optical sensing, yieldinga robust solution for bolt detection.

For embodiments of locking switch 202 that include both inductive coil604 for detecting the locking bolt 702 and RFID coils 506 detecting thelocking tongue 412, different types of metal can be used for the tongue412 and the bolt 702 to ensure that the inductive coil 604 reliablydetects locking bolt 702 without detecting the locking tongue 412. Ingeneral, the metal used to fabricate the locking bolt 702 can be chosenas one having intrinsic properties that cause the inductive coil 604 toinduce a greater frequency shift than those of the metal chosen for thelocking tongue 412. In an example embodiment, locking tongue 412 can bemade of 400 series stainless steel (e.g., 416, 410, etc.), while lockingbolt 702 can be made from 300 series stainless steel. FIG. 11 is a graph1102 that plots sensor inductance shift as a function of sensorfrequency for a variety of materials. The amount of sensor inductanceshift is a function of intrinsic properties of the respective materials.The horizontal line 1104 represents the lack of frequency shift when nometal is present (free space). The top line 1102 represents theinductance shift of stainless steel 416, line 1106 represents theinductance shift of stainless steel 304, and the bottom line representsthe inductance shift of aluminum 1100. If stainless steel 416 andstainless steel 304 are chosen as the materials for locking tongue 412and locking bolt 702, respectively, the relative inductance shiftsmodeled by graph 1102 can be used to find an operating frequency for theinductive sensor (including inductive coil 604) that maximizes detectionof locking bolt 702 while minimizing detection of the locking tongue412; e.g., by selecting a sensor operating frequency corresponding to asufficiently large inductance shift for stainless steel 416 (line 1102)to ensure reliable detection of the locking bolt 702, and a sufficientlysmall inductance shift for stainless steel 304 (line 1106) to ensurethat the locking tongue 412 is not detected by the inductive sensor.

Also, for embodiments in which both inductive coil 604 and RFID coils506 are included in the same locking switch, the tilting of the RFIDcoils 506 due to the slanted surface of bobbin 508 can minimize the riskof interference between the RFID coils 506 and inductive coil 604, sincethe RFID coils are tilted relative to the inductive coil causing thesensing fields of the RFID coils to be directed away from that of theinductive coil. In some embodiments, the RFID coils 506 and inductivecoil 604 can be operated at different operating frequencies (e.g., 500kHz for the inductive coil 604 and 125 kHz for the RFID coils 506) tofurther minimize the risk of interference between the two sensingsystems.

Industrial safety applications can be made more robust if theirassociated locking switches are capable of validating proper operationof their locking bolts. This can include validating that the lockingswitch is capable of reliably confirming the actual position of thelocking bolt. Some locking switches may perform this validation byadvancing the locking bolt to the locked position and then retractingthe bolt back to the unlocked position during a test sequence, andconfirming that the bolt detection signal was properly received.However, since this validation approach requires the locking bolt to beactuated, normal operation of the switch must be interrupted in order tovalidate locking bolt detection. If the locking switch is currentlyholding a safety gate in the closed and locked position, actuating thelocking bolt during this test sequence causes the safety gate to becometemporarily unlocked, creating a potential safety hazard.

To address this issue, one or more embodiments of locking switch 202 caninclude validation circuitry that validates operation of the lockdetection signal without requiring the locking bolt 702 to be actuatedor otherwise interrupting the functionality of the locking switch 202.FIG. 12 is a generalized diagram of an example validation circuit thatincludes diagnostic circuitry capable of confirming the locking switch'sbolt detection capability without interrupting the function of theswitch 202. In this example, the LC tank circuit 1212 used to detect thelocking bolt 702 while in its advanced (locking) position comprises theinductive coil 604 (which can mounted in bobbin 508 in some embodiments,as discussed above) and a capacitor 1210 connected in parallel. Aninductance-to-digital converter (LDC) 1204 (or another type ofconversion component) is connected to the nodes of LC tank circuit 1212and translates the measured frequency of the current signal generated bythe LC circuit 1212 to digital data that is placed on a data bus 1214(e.g., an I2C bus or another type of data bus). This frequency signal isindicative of the inductance of coil 604, which in turn is a function ofthe presence or absence of locking bolt 702 within the magnetic field ofinductive coil 604. Although FIG. 12 depicts an LDC 1204 as theconversion component used to translate the current signal frequency todigital data, other types of conversion components can also be used togenerate a digital value proportionate to the current signal frequencyin some embodiments.

A master controller 1202 on the data bus 1214 monitors the digitalfrequency signal on the data bus 1214 and confirms that the locking bolt702 has properly advanced—or has properly retracted—based on measuredchanges to the digital frequency value. For reliability purposes, someembodiments may also include a watchdog controller 1208 that is tied tothe data bus 1214 and performs redundant monitoring of the digitalfrequency signal. In some embodiments, both the master controller 1202and the watchdog controller 1208 may perform parallel independentmonitoring of the digital frequency signal and collectively confirm theposition of the locking bolt 702 only if both controllers 1202 and 1208reach the same conclusion. In some embodiments, the master controller1202 and/or the watchdog controller generates a confirmation signal inresponse to this confirmation that the locking bolt 702 has advanced.

To verify that this locking bolt validation system is reliablymonitoring and reporting the state of the locking bolt, a diagnosticcapacitor 1216 is connected to the LC tank circuit 1212 via a diagnosticswitch 1206 (e.g., a solid state switching device). Diagnostic capacitor1216 remains isolated from the LC tank circuit 1212 while the diagnosticswitch 1206 is disabled. During a diagnostic sequence initiated andcontrolled by the master controller 1202, the diagnostic switch 1206 isenabled (e.g., by a signal applied to the diagnostic switch's Enableinput by master controller 1202), which causes the diagnostic capacitor1216 to be electrically connected to the LC tank circuit 1212 inparallel with capacitor 1210. The capacitance of diagnostic capacitor1216 is sized such that connecting the diagnostic capacitor 1216 inparallel with tank capacitor 1210 creates a shift in the frequency ofthe current signal through the LC tank circuit 1212 that is roughly theequivalent of the frequency shift caused by the presence of the lockingbolt 702 within the magnetic field of coil 604. That is, whereasadvancement of locking bolt 702 to the locked position changes theinductance of coil 604 in a manner that alters the frequency of thecurrent through the LC tank circuit 1212 by a predictable frequencyshift magnitude, connecting diagnostic capacitor 1216 to the LC tankcircuit 1212 (by enabling diagnostic switch 1206) changes thecapacitance of the LC tank circuit 1212 in a manner that alters thefrequency by a substantially equal frequency shift magnitude.

During the diagnostic sequence, master controller 1202 can enable thediagnostic switch 1206 and monitor the digital frequency value generatedby the LDC 1204 to verify that the frequency value changes as expected.For example, during normal operation of the locking switch 202 themaster controller 1202 can monitor the digital frequency value on bus1214 and, in response to determining that the frequency value changes bya defined frequency shift magnitude indicative of the presence of thelocking bolt within the coil's magnetic field, generate a confirmationsignal indicating that the locking bolt 702 has been advanced. Thedefined frequency shift magnitude may be defined as a valid frequencyshift range to allow for small frequency variations.

During a diagnostic sequence, master controller 1202 can enablediagnostic switch 1106 and, in response to determining that the digitalfrequency value shifts by the defined frequency shift magnitude (withina defined tolerance) within an expected time duration after enabling thediagnostic switch 1206, confirm that the locking bolt validation systemis operating properly and is capable of reliable detecting the state ofthe locking bolt 702. Alternatively, if the master controller 1202determines that the digital frequency value has not shifted by thedefined frequency shift magnitude within the defined time duration afterenabling the diagnostic switch 1206, the master controller 1202generates an error signal. The error signal may include an error messagerendered on a client device indicating that the locking bolt validationsystem is not working properly, or may be an error signal sent to anexternal safety or control system. This diagnostic sequence can beperformed regardless of whether the locking bolt 702 is currentlyadvanced or retracted, and does not require the locking bolt 702 to bephysically actuated in order to validate the LC tank circuit 1212 andits associated LDC 1204. During the diagnostic sequence, any controloutputs from the locking switch 202 that would otherwise be generated inresponse to detecting that the locking bolt has been advanced aredisabled to prevent false indications being sent to external control orsafety systems.

In contrast to locking switches that employ two separate optical sensorsto detect the locking bolt's lock and unlock positions, respectively,the use of an inductive sensor (LC tank circuit 1212) with associateddiagnostic circuitry requires only a single sensor to confirm theposition of the locking bolt 702 in a robust and reliable manner.

FIG. 13 is a generalized diagram of another example embodiment oflocking bolt validation circuit including diagnostic circuitry. Thisexample embodiment adds a separate diagnostic controller 1302 so thatoperation of the master controller 1202 and watchdog controller 1208 isincluded in the scope of validation. In contrast to the embodimentdepicted in FIG. 12, the enable signal that controls the state ofdiagnostic switch 1206 is generated by this new diagnostic controller1302 rather than by master controller 1202. Diagnostic controller 1302validates operation of the locking bolt detection circuitry bymonitoring outputs of the master controller 1202 and watchdog controller1208 rather than by monitoring the digital frequency signal directly asin the embodiment depicted in FIG. 12.

In this embodiment, during the diagnostic sequence, diagnosticcontroller 1302 enables switch 1206 and monitors the detection signalsgenerated master controller 1202 and watchdog controller 1208. Eachcontroller 1202 and 1208 generates its detection signal in response todetecting the expected shift in the digital frequency signal caused byswitching the diagnostic capacitor 1216 to the LC tank circuit 1212. Ifthe detection signals from both the master controller 1202 and watchdogcontroller 1208 indicate that the expected frequency shift has beendetected within a defined time duration after generating the enablesignal, diagnostic controller 1302 determines that the locking boltdetection circuitry is operating properly. Alternatively, if diagnosticcontroller 1302 does not received one or both of the detection signalsfrom the master controller 1202 or the watchdog controller 1208 withinthe defined time duration after initiating the enable signal, thediagnostic controller 1302 determines that the locking bolt detectioncircuitry is not functioning properly and generates an error signal.

The various sensing and validation features described herein can be usedcollectively in a single locking switch in some embodiments. Otherembodiments may comprise locking switches that incorporate only a subsetof the disclosed sensing and validation features. For example, someembodiments of the disclosed locking switch 202 may include both RFIDcoils 506 and inductive coil 604. Other embodiments may incorporate onlythe RFID coils 506 without including inductive coil 604, while stillother embodiments may include only the inductive coil 604 withoutincluding RFID coils 506. Moreover, while embodiments of locking switch202 have been described herein as including three locking tongue entryslots 204, some embodiments may include more than three tongue entryslots 204 (and corresponding RFID coils 506) without departing from thescope of one or more embodiments. Some embodiments may also compriseonly two tongue entry slots and corresponding RFID coils 506.

FIGS. 14-15 illustrate methodologies in accordance with one or moreembodiments of the subject application. While, for purposes ofsimplicity of explanation, the methodologies shown herein are shown anddescribed as a series of acts, it is to be understood and appreciatedthat the subject innovation is not limited by the order of acts, as someacts may, in accordance therewith, occur in a different order and/orconcurrently with other acts from that shown and described herein. Forexample, those skilled in the art will understand and appreciate that amethodology could alternatively be represented as a series ofinterrelated states or events, such as in a state diagram. Moreover, notall illustrated acts may be required to implement a methodology inaccordance with the innovation. Furthermore, interaction diagram(s) mayrepresent methodologies, or methods, in accordance with the subjectdisclosure when disparate entities enact disparate portions of themethodologies. Further yet, two or more of the disclosed example methodscan be implemented in combination with each other, to accomplish one ormore features or advantages described herein.

FIG. 14 is an example methodology 1400 for detecting insertion of alocking tongue of an actuator assembly into an industrial locking switchfrom any of three different directions of approach. At 1402, adetermination is made as to whether an RFID tag mounted on a lockingtongue of an actuator assembly is detected by any of a first RFID coillocated inside a first entry slot of an industrial locking switch, asecond RFID coil located inside a second entry slot of the industriallocking switch, or a third RFID coil located inside a third entry slotof the industrial locking switch. If the RFID tag is not detected by anyof the three RFID coils (NO at step 1402), step 1402 repeats until anyof the three RFID coils detects the RFID tag (YES at step 1402), causingthe methodology to proceed to step 1404, where a confirmation signalindicating that the locking tongue has been inserted into one of theentry slots is generated. In an example implementation, the confirmationsignal may be an interlock signal sent to an external or internalcontrol system that controls the position of the locking switch'slocking bolt, such that the locking bolt is engaged only if theconfirmation signal is received. The first, second, and third RFID coilscan be electrically connected together in series, and the determinationsas to whether the RFID tag has been detected by any of the three RFIDcoils can be made by detection circuitry based on measured modulationsinduced on a current through the coils as a result of disturbances tothe coils' electromagnetic fields by the RFID tag.

FIG. 15 is an example methodology 1500 for validating correct operationof an inductive sensor used to detect the position of the locking boltof an industrial locking switch. Initially, at 1502, a position of thelocking bolt is detected based on measurement of a frequency shift ofthe inductive sensor's current, where this frequency shift is caused bypresence of the locking bolt within a magnetic field of the inductivesensor. In an example implementation, the inductive sensor may comprisean LC tank circuit having an inductive coil positioned such that thelocking bolt enters the inductive coil's magnetic field when advanced tothe locked position.

At 1504, a determination is made as to whether a diagnostic test of theinductive sensor is initiated. If the diagnostic test is not initiated(NO at step 1504), the methodology returns to step 1502 and the lockingswitch continues to operate normally, with the inductive sensordetecting when the locking bolt is in the advanced (locked) positionduring normal operation. If the diagnostic test is initiated (YES atstep 1504), the methodology proceeds to step 1506, where a diagnosticswitch is enabled that electrically connects a diagnostic capacitor tothe inductive sensor. Electrically connecting the diagnostic capacitorchanges the capacitance of the inductive sensor in a manner thatreplicates the frequency shift induced by the presence of the lockingbolt during normal operation.

At 1508, a determination is made as to whether a frequency shift similarto that caused by presence of the locking bolt in its locked position isdetected. If such a frequency shift is detected (YES at step 1508),operation of the inductive sensor is validated and the methodologyreturns to step 1502. If the frequency shift is not detected (NO at step1508), the methodology proceeds to step 1510, where a determination ismade as to whether a defined time duration has elapsed since enablingthe diagnostic switch at step 1506. If the defined duration has notelapsed (NO at step 1510), the methodology returns to step 1508 and theinductive sensor continues to be monitored for the expected frequencyshift. Steps 1508 and 1510 repeat until either the frequency shift isdetected at step 1508 (thereby validating operation of the inductivesensor) or the defined time duration elapses at step 1510. If theexpected frequency shift is not detected before the defined timeduration has elapsed (YES at step 1510), the methodology proceeds tostep 1512, where an error signal is generated indicating that operationof the inductive sensor cannot be validated.

Embodiments, systems, and components described herein, as well asindustrial control systems and industrial automation environments inwhich various aspects set forth in the subject specification can becarried out, can include computer or network components such as servers,clients, programmable logic controllers (PLCs), automation controllers,communications modules, mobile computers, wireless components, controlcomponents and so forth which are capable of interacting across anetwork. Computers and servers include one or more processors—electronicintegrated circuits that perform logic operations employing electricsignals—configured to execute instructions stored in media such asrandom access memory (RAM), read only memory (ROM), a hard drives, aswell as removable memory devices, which can include memory sticks,memory cards, flash drives, external hard drives, and so on.

Similarly, the term PLC or automation controller as used herein caninclude functionality that can be shared across multiple components,systems, and/or networks. As an example, one or more PLCs or automationcontrollers can communicate and cooperate with various network devicesacross the network. This can include substantially any type of control,communications module, computer, Input/Output (I/O) device, sensor,actuator, instrumentation, and human machine interface (HMI) thatcommunicate via the network, which includes control, automation, and/orpublic networks. The PLC or automation controller can also communicateto and control various other devices such as standard or safety-ratedI/O modules including analog, digital, programmed/intelligent I/Omodules, other programmable controllers, communications modules,sensors, actuators, output devices, and the like.

The network can include public networks such as the internet, intranets,and automation networks such as Common Industrial Protocol (CIP)networks including DeviceNet, ControlNet, and Ethernet/IP. Othernetworks include Ethernet, DH/DH+, Remote I/O, Fieldbus, Modbus,Profibus, CAN, wireless networks, serial protocols, near fieldcommunication (NFC), Bluetooth, and so forth. In addition, the networkdevices can include various possibilities (hardware and/or softwarecomponents). These include components such as switches with virtuallocal area network (VLAN) capability, LANs, WANs, proxies, gateways,routers, firewalls, virtual private network (VPN) devices, servers,clients, computers, configuration tools, monitoring tools, and/or otherdevices.

In order to provide a context for the various aspects of the disclosedsubject matter, FIGS. 16 and 17 as well as the following discussion areintended to provide a brief, general description of a suitableenvironment in which the various aspects of the disclosed subject mattermay be implemented.

With reference to FIG. 16, an example environment 1610 for implementingvarious aspects of the aforementioned subject matter includes a computer1612. The computer 1612 includes a processing unit 1614, a system memory1616, and a system bus 1618. The system bus 1618 couples systemcomponents including, but not limited to, the system memory 1616 to theprocessing unit 1614. The processing unit 1614 can be any of variousavailable processors. Multi-core microprocessors and othermultiprocessor architectures also can be employed as the processing unit1614.

The system bus 1618 can be any of several types of bus structure(s)including the memory bus or memory controller, a peripheral bus orexternal bus, and/or a local bus using any variety of available busarchitectures including, but not limited to, 8-bit bus, IndustrialStandard Architecture (ISA), Micro-Channel Architecture (MSA), ExtendedISA (EISA), Intelligent Drive Electronics (IDE), VESA Local Bus (VLB),Peripheral Component Interconnect (PCI), Universal Serial Bus (USB),Advanced Graphics Port (AGP), Personal Computer Memory CardInternational Association bus (PCMCIA), and Small Computer SystemsInterface (SCSI).

The system memory 1616 includes volatile memory 1620 and nonvolatilememory 1622. The basic input/output system (BIOS), containing the basicroutines to transfer information between elements within the computer1612, such as during start-up, is stored in nonvolatile memory 1622. Byway of illustration, and not limitation, nonvolatile memory 1622 caninclude read only memory (ROM), programmable ROM (PROM), electricallyprogrammable ROM (EPROM), electrically erasable PROM (EEPROM), or flashmemory. Volatile memory 1620 includes random access memory (RAM), whichacts as external cache memory. By way of illustration and notlimitation, RAM is available in many forms such as synchronous RAM(SRAM), dynamic RAM (DRAM), synchronous DRAM (SDRAM), double data rateSDRAM (DDR SDRAM), enhanced SDRAM (ESDRAM), Synchlink DRAM (SLDRAM), anddirect Rambus RAM (DRRAM).

Computer 1612 also includes removable/non-removable,volatile/non-volatile computer storage media. FIG. 16 illustrates, forexample a disk storage 1624. Disk storage 1624 includes, but is notlimited to, devices like a magnetic disk drive, floppy disk drive, tapedrive, Jaz drive, Zip drive, LS-100 drive, flash memory card, or memorystick. In addition, disk storage 1624 can include storage mediaseparately or in combination with other storage media including, but notlimited to, an optical disk drive such as a compact disk ROM device(CD-ROM), CD recordable drive (CD-R Drive), CD rewritable drive (CD-RWDrive) or a digital versatile disk ROM drive (DVD-ROM). To facilitateconnection of the disk storage 1624 to the system bus 1618, a removableor non-removable interface is typically used such as interface 1626.

It is to be appreciated that FIG. 16 describes software that acts as anintermediary between users and the basic computer resources described insuitable operating environment 1610. Such software includes an operatingsystem 1628. Operating system 1628, which can be stored on disk storage1624, acts to control and allocate resources of the computer 1612.System applications 1630 take advantage of the management of resourcesby operating system 1628 through program modules 1632 and program data1634 stored either in system memory 1616 or on disk storage 1624. It isto be appreciated that one or more embodiments of the subject disclosurecan be implemented with various operating systems or combinations ofoperating systems.

A user enters commands or information into the computer 1612 throughinput device(s) 1636. Input devices 1636 include, but are not limitedto, a pointing device such as a mouse, trackball, stylus, touch pad,keyboard, microphone, joystick, game pad, satellite dish, scanner, TVtuner card, digital camera, digital video camera, web camera, and thelike. These and other input devices connect to the processing unit 1614through the system bus 1618 via interface port(s) 1638. Interfaceport(s) 1638 include, for example, a serial port, a parallel port, agame port, and a universal serial bus (USB). Output device(s) 1640 usesome of the same type of ports as input device(s) 1636. Thus, forexample, a USB port may be used to provide input to computer 1612, andto output information from computer 1612 to an output device 1640.Output adapters 1642 are provided to illustrate that there are someoutput devices 1640 like monitors, speakers, and printers, among otheroutput devices 1640, which require special adapters. The output adapters1642 include, by way of illustration and not limitation, video and soundcards that provide a means of connection between the output device 1640and the system bus 1618. It should be noted that other devices and/orsystems of devices provide both input and output capabilities such asremote computer(s) 1644.

Computer 1612 can operate in a networked environment using logicalconnections to one or more remote computers, such as remote computer(s)1644. The remote computer(s) 1644 can be a personal computer, a server,a router, a network PC, a workstation, a microprocessor based appliance,a peer device or other common network node and the like, and typicallyincludes many or all of the elements described relative to computer1612. For purposes of brevity, only a memory storage device 1646 isillustrated with remote computer(s) 1644. Remote computer(s) 1644 islogically connected to computer 1612 through a network interface 1648and then physically connected via communication connection 1650. Networkinterface 1648 encompasses communication networks such as local-areanetworks (LAN) and wide-area networks (WAN). LAN technologies includeFiber Distributed Data Interface (I-DDI), Copper Distributed DataInterface (CDDI), Ethernet/IEEE 802.3, Token Ring/IEEE 802.5 and thelike. WAN technologies include, but are not limited to, point-to-pointlinks, circuit switching networks like Integrated Services DigitalNetworks (ISDN) and variations thereon, packet switching networks, andDigital Subscriber Lines (DSL). Network interface 1648 can alsoencompass near field communication (NFC) or Bluetooth communication.

Communication connection(s) 1650 refers to the hardware/softwareemployed to connect the network interface 1648 to the system bus 1618.While communication connection 1650 is shown for illustrative clarityinside computer 1612, it can also be external to computer 1612. Thehardware/software necessary for connection to the network interface 1648includes, for exemplary purposes only, internal and externaltechnologies such as, modems including regular telephone grade modems,cable modems and DSL modems, ISDN adapters, and Ethernet cards.

FIG. 17 is a schematic block diagram of a sample computing environment1700 with which the disclosed subject matter can interact. The samplecomputing environment 1700 includes one or more client(s) 1702. Theclient(s) 1702 can be hardware and/or software (e.g., threads,processes, computing devices). The sample computing environment 1700also includes one or more server(s) 1704. The server(s) 1704 can also behardware and/or software (e.g., threads, processes, computing devices).The servers 1704 can house threads to perform transformations byemploying one or more embodiments as described herein, for example. Onepossible communication between a client 1702 and servers 1704 can be inthe form of a data packet adapted to be transmitted between two or morecomputer processes. The sample computing environment 1700 includes acommunication framework 1706 that can be employed to facilitatecommunications between the client(s) 1702 and the server(s) 1704. Theclient(s) 1702 are operably connected to one or more client datastore(s) 3208 that can be employed to store information local to theclient(s) 1702. Similarly, the server(s) 1704 are operably connected toone or more server data store(s) 1710 that can be employed to storeinformation local to the servers 1704.

What has been described above includes examples of the subjectinnovation. It is, of course, not possible to describe every conceivablecombination of components or methodologies for purposes of describingthe disclosed subject matter, but one of ordinary skill in the art mayrecognize that many further combinations and permutations of the subjectinnovation are possible. Accordingly, the disclosed subject matter isintended to embrace all such alterations, modifications, and variationsthat fall within the spirit and scope of the appended claims.

In particular and in regard to the various functions performed by theabove described components, devices, circuits, systems and the like, theterms (including a reference to a “means”) used to describe suchcomponents are intended to correspond, unless otherwise indicated, toany component which performs the specified function of the describedcomponent (e.g., a functional equivalent), even though not structurallyequivalent to the disclosed structure, which performs the function inthe herein illustrated exemplary aspects of the disclosed subjectmatter. In this regard, it will also be recognized that the disclosedsubject matter includes a system as well as a computer-readable mediumhaving computer-executable instructions for performing the acts and/orevents of the various methods of the disclosed subject matter.

In addition, while a particular feature of the disclosed subject mattermay have been disclosed with respect to only one of severalimplementations, such feature may be combined with one or more otherfeatures of the other implementations as may be desired and advantageousfor any given or particular application. Furthermore, to the extent thatthe terms “includes,” and “including” and variants thereof are used ineither the detailed description or the claims, these terms are intendedto be inclusive in a manner similar to the term “comprising.”

In this application, the word “exemplary” is used to mean serving as anexample, instance, or illustration. Any aspect or design describedherein as “exemplary” is not necessarily to be construed as preferred oradvantageous over other aspects or designs. Rather, use of the wordexemplary is intended to present concepts in a concrete fashion.

Various aspects or features described herein may be implemented as amethod, apparatus, or article of manufacture using standard programmingand/or engineering techniques. The term “article of manufacture” as usedherein is intended to encompass a computer program accessible from anycomputer-readable device, carrier, or media. For example, computerreadable media can include but are not limited to magnetic storagedevices (e.g., hard disk, floppy disk, magnetic strips . . . ), opticaldisks [e.g., compact disk (CD), digital versatile disk (DVD) . . . ],smart cards, and flash memory devices (e.g., card, stick, key drive . .. ).

What is claimed is:
 1. A locking switch, comprising: a solenoid-drivenlocking bolt configured to engage with an engagement hole of a lockingtongue when advanced to a locking position; and an inductive sensorsystem configured to detect that the locking bolt has advanced to thelocking position, wherein the inductive sensor system comprises a tankcircuit comprising an inductive coil and a capacitor, the inductive coiloriented to receive the locking tongue when the locking tongue isadvanced to the locking position, a converter configured to convert afrequency of a current signal on the tank circuit to a digital frequencyvalue, and a master controller configured to generate a lock detectionsignal in response to determining that a shift in the digital frequencyvalue corresponds to an expected frequency shift of the current signalinduced by the inductive coil in response to advancement of the lockingbolt; and a diagnostic system configured to confirm operation of theinductive sensor system, the diagnostic system comprising a diagnosticcapacitor and a diagnostic switch configured to connect the diagnosticcapacitor to the tank circuit in parallel with the capacitor.
 2. Thelocking switch of claim 1, wherein the diagnostic system furthercomprises the master controller, and the master controller is furtherconfigured to: enable the diagnostic switch causing the diagnosticcapacitor to electrically connect to the tank circuit in parallel withthe capacitor, and in response to determining that the digital frequencyvalue does not shift by the expected frequency shift within a definedtime duration after enabling the diagnostic switch, generate an errorsignal indicating that the inductive sensor system is faulted.
 3. Thelocking switch of claim 1, wherein the diagnostic system furthercomprises a diagnostic controller configured to: enable the diagnosticswitch causing the diagnostic capacitor to electrically connect to thetank circuit in parallel with the capacitor, and in response todetermining that the master controller does not generate the lockdetection signal within a defined time duration after enabling thediagnostic switch, generate an error signal indicating that theinductive sensor system is faulted.
 4. The locking switch of claim 1,wherein the inductive sensor system further comprises a watchdogcontroller configured to perform redundant monitoring of the digitalfrequency signal, and the master controller is configured to generatethe lock detection signal in response to determining that the mastercontroller and the watchdog controller confirm that the shift in thedigital frequency value corresponds to the expected frequency shift. 5.The locking switch of claim 1, wherein the diagnostic capacitor has acapacitance that, in response to connection of the diagnostic capacitorto the tank circuit in parallel with the capacitor, causes the frequencyof the current signal to shift by the expected frequency shift inducedby the inductive coil in response to advancement of the locking bolt. 6.The locking switch of claim 1, wherein the inductive coil is mountedaround a central opening of a bobbin mounted inside a housing of thelocking switch, and the bobbin is positioned such that the locking boltpasses through the central opening and the inductive coil when thelocking bolt is advanced.
 7. The locking switch of claim 6, furthercomprising at least one radio frequency identifier (RFID) coilconfigured to detect insertion of the locking tongue into an entry slotof the locking switch.
 8. The locking switch of claim 7, wherein the atleast one RFID coil is mounted on a top surface of the bobbin that isslanted relative to a bottom surface of the bobbin, and the top surfacetilts the at least one RFID coil relative to the inductive coil.
 9. Thelocking switch of claim 7, wherein a first operating frequency of theRFID coil is different than a second operating frequency of theinductive coil.
 10. The locking switch of claim 1, wherein the lockingbolt comprises a first metal and the locking tongue comprises a secondmetal, and the first metal causes the inductive coil to induce a greaterfrequency shift of the current signal than the second metal.
 11. Asystem for sensing a position of a locking bolt of an industrial lockingswitch, comprising: an inductive circuit comprising an inductive coiland a capacitor electrically connected in parallel, wherein theinductive coil is positioned to receive a locking bolt of an industriallocking switch when the locking bolt is transitioned to a lock position;a converter configured to convert a frequency of a current signal on theinductive circuit to a digital frequency value; a master controllerconfigured to generate a bolt detection signal in response todetermining that the digital frequency value changes by an amount equalto or substantially equal to a defined frequency shift corresponding toa frequency shift induced by the inductive coil in response to presenceof the locking bolt within the inductive coil's magnetic field; and adiagnostic system configured to validate operation of the inductivecircuit and the converter, the diagnostic system comprising a diagnosticcapacitor and a diagnostic switch configured to electrically connect thediagnostic capacitor to the inductive circuit in parallel with thecapacitor.
 12. The system of claim 11, wherein the master controller isfurther configured to: enable the diagnostic switch causing thediagnostic capacitor to electrically connect to the inductive circuit inparallel with the capacitor, and in response to determining that thedigital frequency value does not change by the amount equal to orsubstantially equal to the defined frequency shift within a defined timeduration after enabling the diagnostic switch, generate an error signalindicating that the inductive circuit or the converter is faulted. 13.The system of claim 11, wherein the diagnostic system further comprisesa diagnostic controller configured to: enable the diagnostic switchcausing the diagnostic capacitor to electrically connect to theinductive circuit in parallel with the capacitor, and in response todetermining that the master controller does not generate the boltdetection signal within a defined time duration after enabling thediagnostic switch, generate an error signal indicating that theinductive circuit or the converter is faulted.
 14. The system of claim11, wherein the diagnostic capacitor has a capacitance that, in responseto connection of the diagnostic capacitor to the inductive circuit inparallel with the capacitor, causes the frequency of the current signalto shift by the defined frequency shift.
 15. The system of claim 11,wherein the inductive coil is mounted in a central opening of a bobbinmounted inside a housing of the locking switch, and the bobbin isoriented to cause the locking bolt to pass through the central openingand the inductive coil when the locking bolt is transitioned to the lockposition.
 16. The system of claim 15, wherein a first operatingfrequency of the inductive coil is different than a second operatingfrequency of a radio frequency identifier (RFID) coil mounted on thebobbin and configured to detect insertion of a locking tongue into thelocking switch.
 17. A method for validating operation of a locking boltdetection system, comprising: performing a diagnostic test of aninductive sensing circuit configured to detect that a locking bolt of anindustrial locking switch has advanced to a locking position, whereinthe inductive sensing circuit comprises a capacitor and an inductivecoil, and wherein the performing of the diagnostic test comprisesconnecting a diagnostic capacitor in parallel with the capacitor of theinductive sensing circuit; and in response to determining that afrequency of a current signal through the inductive sensing circuit doesnot change, within a defined duration after the connecting of thediagnostic capacitor, by an amount equal to or substantially equal to afrequency shift caused by presence of the locking bolt in the inductivecoil's magnetic field, generating an error message indicating that theinductive sensing circuit is not operating correctly.
 18. The method ofclaim 17, wherein the connecting comprises enabling a diagnostic switchthat electrically connects the diagnostic capacitor to the inducivesensing circuit.
 19. The method of claim 17, further comprisingconverting the frequency of the current signal to a digital frequencyvalue, wherein the determining that the frequency of the current signaldoes not change comprises monitoring the digital frequency value. 20.The method of claim 17, wherein the generating the error signalcomprises sending the error signal to at least one of an industrialsafety system or an industrial control system.